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Precision is critical in many industries, and custom metal extrusion delivers. The process allows for tight tolerances and consistent quality, ensuring that each part meets exact specifications.
One of the standout advantages of custom metal extrusion is the ability to produce highly complex and intricate designs. Whether it's a unique shape or a specific size, custom extrusion can accommodate a wide range of design needs.
Compared to other manufacturing processes, custom metal extrusion can be more cost-effective, especially for large production runs. The ability to produce parts quickly and accurately reduces waste and lowers overall production costs.
Custom metal extrusion is a process where you take metal and push it through a die to make something that has a fixed cross-sectional profile. You can make complex shapes and designs with custom extrusion that you can’t make with other manufacturing processes.
Aluminum is the most commonly extruded material. About 80% of all extruded metal products are made from aluminum. It can be hot or cold extruded. If it is hot extruded, it is heated to 575 to 1100 °F (300 to 600 °C). Examples of products include profiles for tracks, frames, rails, mullions, and heat sinks. Its versatility and ease of extrusion make aluminum the preferred choice for many applications.
If you need stainless steel, brass, copper, or other metal extrusions, we’re happy to talk to you about them and see if we can help.
This finishing option is the fastest available. Parts may have visible tool marks and possibly sharp edges or burrs, removable on request.
You can use sandblasting to peel paint, smooth out rust, take bumps and mars from stuff, and basically make things clean. Ironically, you can also sandblast things to scuff them up by etching the surface and give something a little bit of ‘tooth’ so that paint will stick better.
Type II anodizing enhances corrosion resistance. It allows parts to be colored in various shades like clear, black, red, and gold, typically for aluminum. Type III provides a thicker, wear-resistant layer as well as the corrosion resistance of Type II.
This process involves spraying powdered paint onto a part, which is then heated in an oven. The result is a tough, wear- and corrosion-resistant coating, more robust than traditional paint methods. A broad range of colors is available for achieving the desired look.
Plating involves coating a conductive surface with a thin metal layer. This method is often used to prevent corrosion, enhance durability, modify surface friction, and boost aesthetics.
Can't find the finish you require? Send us an RFQ, and we'll explore a finishing solution for you.
Tolerances as precise as +/- .005mm on one or more dimensions of an extrusion, depending on its shape.
You can make walls as thin as 0.4 mm on one or more dimensions of an extrusion, depending on its the shape.
Few extruders can handle 1.2mm holes with +/- 0.03mm tolerances, but many trust Partzcore with this challenge.
Custom metal extrusions are used in numerous applications, from automotive components to architectural elements, electronics, and aerospace parts. The versatility of this process makes it invaluable for industries requiring precision and customizability.
Preparation and Planning
The extrusion process begins with careful planning and design. This involves creating detailed blueprints and selecting the appropriate materials.
The Extrusion Process
During extrusion, the chosen metal is heated until it becomes malleable. It is then forced through a die, forming the desired shape. This step requires precise control to ensure the final product matches the design specifications.
Post-Extrusion Treatments
After extrusion, the parts may undergo various treatments, such as cooling, cutting, and surface finishing, to enhance their properties and appearance.
Meeting Tight Deadlines
In many industries, project timelines are tight, and delays can be costly. Fast turnaround times ensure that projects stay on schedule and within budget.
Reducing Downtime
Downtime can be detrimental to production efficiency. Quick production of custom metal extrusions helps minimize downtime, keeping operations running smoothly.
Improving Project Efficiency
A fast turnaround improves overall project efficiency, allowing companies to move quickly from design to production and delivery.
Key Differences
Custom metal extrusion is tailored to specific design requirements, whereas standard extrusion uses predefined shapes and sizes.
Advantages of Custom Solutions
Custom solutions offer greater flexibility and precision, allowing for the creation of unique and specialized parts that standard extrusion cannot achieve.
Industries such as automotive, aerospace, electronics, and construction benefit significantly from custom metal extrusion due to the precision and flexibility it offers.
Prototype aluminum extrusions allow manufacturers to test designs and make necessary adjustments before committing to full-scale production. This can save time and money by identifying potential issues early in the development process. Additionally, the quick turnaround time for prototypes helps speed up the overall project timeline.
Prototyping with aluminum extrusions offers several benefits:
Extrusion dies are relatively cheaper than die-cast molds and are easier to make. Extrusion is an adaptable and cheaper process that can be adjusted at short notice. This makes extrusion ideal for shorter production runs. In contrast, die-casting is more cost-prohibitive due to the complexity and expense of creating the molds.
Die casting involves forcing molten metal into a mold under high pressure. The molds used in die casting are typically made of hardened steel and can be very expensive to produce. Additionally, the die-casting process requires specialized equipment and can have higher operating costs compared to extrusion.
Extrusion, on the other hand, uses dies that are typically made of softer materials such as tool steel or even aluminum for short production runs. The lower cost of dies and the simplicity of the extrusion process make it a more economical option for many applications. This cost advantage is particularly significant for small to medium-sized production runs where the high initial cost of die casting molds cannot be justified.
Metal extrusion is significantly cheaper than other metal processes like CNC machining, which is much more cost-prohibitive to produce metal parts at scale. Extrusion offers a cost-effective solution for creating complex profiles and shapes without the high costs associated with other manufacturing methods.
The cost advantages of extrusion include:
Contact Partzcore (sales@partzcore.com) to get a free quote and expert advice on custom metal parts. Our team will provide the right solution for your project.
Please share your specific needs with us, including drawings, reference images, and your ideas, so we can turn them into reality.
We will analyze your requirements and drawings to provide the optimal solution, along with a detailed quote within 24 hours.
Upon receiving your approval and deposit, we will proceed with mass production and manage the shipping process.
Contact Partzcore (sales@partzcore.com) to get a free quote and expert advice on custom metal parts. Our team will provide the right solution for your project.